EP2736703A1

EP2736703A1 - A device for the manufacture of a bonded component with fibre-reinforced plastics and also a method

Info

Publication number: EP2736703A1
Application number: EP12740598.3A
Authority: EP
Inventors: Heinz Bardenhagen
Original assignee: Airbus Operations GmbH
Current assignee: Airbus Operations GmbH
Priority date: 2011-07-27
Filing date: 2012-07-27
Publication date: 2014-06-04
Also published as: WO2013014283A1; DE102011079928A1; US20140374012A1

Abstract

Device (40) for the manufacture of a bonded component (52) with fibre-reinforced plastics with at least one base moulding tool (42) and at least one moulding tool (54), wherein the bonded component (52) is arranged between the base moulding tool (42) and the moulding tool (54), and the bonded component (52) has at least one base laminate (48) and at least one reinforcement laminate (50), and the moulding tool (54) is covered with an aeration material (78) and with a vacuum envelope (80), wherein the vacuum envelope (80) is sealed with respect to the base moulding tool (42). At least one moulding tool (54) is at least partially formed from a metal alloy, which has an anomalous thermal expansion coefficient, By this means undesirable lost cavities in the device (40) are reduced. A method for the manufacture of a bonded component (52) is also disclosed.

Description

DESCRIPTION

A device for the manufacture of a bonded component with

fibre-reinforced plastics and also a method

The invention concerns a device for the manufacture of a bonded component with fibre-reinforced plastics with at least one base moulding tool and at least one moulding tool, wherein the bonded component is arranged between the base moulding tool and the moulding tool and the bonded component has at least one base laminate and at least one reinforcement laminate, and the moulding tool is covered with an aeration material and with a vacuum envelope, wherein the vacuum envelope is sealed with respect to the base moulding tool.

For components in which high strengths and stiffnesses are required per unit weight, as, for example, in aerospace applications, fibre-reinforced plastics (FRPs) are often deployed. A fibre-reinforced plastic is a material that is formed with a multiplicity of reinforcing fibres that are embedded in a plastic matrix material. At the present time carbon fibres, glass fibres, aramide^® fibres, natural fibres, or similar, are, amongst others, deployed as the reinforcing fibres. As a rule the matrix material consists of thermosetting plastics, such as, for example, epoxy resins, polyester resins, phenol resins, or bismaleimide resins (so-called BMI resins) . The bonded components can be manufactured with reinforcing fibres that are already pre- impregnated with matrix material (so-called prepreg material, prepreg semi-finished products), and/or with reinforcing fibres, i.e. fibre products, with a suitable geometry, which are only infiltrated, i.e. impregnated, with the matrix material immediately before the curing process. Complex, integral fibre-reinforced plastic structures usually consist of at least one base laminate with a multiplicity of reinforcing and connecting components. These elements can be available as fibre- reinforced plastic components that have already been consolidated, as components of other materials, and also as fibre-reinforced plastic laminates. Fibre-reinforced plastic laminates consist of two or more layers of reinforcing fibres that have been pre-impregnated with a matrix material, and which are not yet cured. The reinforcing fibres can be available as a unidirectional layer, a woven fabric, a knitted fabric, or a multi-layer mat. The layers usually have differing primary fibre directions with a course that is preferably aligned with the forces that are occurring.

One variant for the design of components from fibre- reinforced plastics is, for example, a large-format shell with longitudinal stiffeners, in particular I-stringers, or stringers with cross-sectional geometries that differ from the latter, in an integral form of construction. These are constructed from at least one base laminate and reinforcement laminates, such as, for example, stringer laminates, and also from partial reinforcements and other features as required.

Shells stiffened with I-stringers in an integral form of construction are components that are often spherically curved. Through the design of the base laminate, the use of reinforcements and insulation material, and also the addition of other elements, components of complex shape ensue, with very different thicknesses and contours in some sections. Such shell components find application, for example, in the manufacture of lifting surfaces, ailerons, landing flaps, elevator units, vertical tail units, fuselage shells, or similar items for the production of aircraft .

For the manufacture of a shell component with integral reinforcing elements, such as, for example, stringers, the stringer laminates are laid down in accordance with a procedure of known prior art - here cited in an exemplary manner - on moulding tools fitted with means of release, and are shaped on the latter. In a further operation a base laminate is laid down on a base moulding tool similarly fitted with means of release, and is aligned on the latter. The moulding tools are then brought together, spatially aligned, and as a unit are together laid down on the base laminate. The whole arrangement is then fitted with a vacuum generation system and the device thus created is introduced into an autoclave for purposes of full curing at high pressure and temperature. The removal of the bonded component from the device represents the final production step. Parasitic voids represent a major difficulty in the production of integrally reinforced shells; these are already present within the device, or occur only during the curing process. In particular matrix material can penetrate into these voids; in turn this leads to a reduction of the material thickness of the bonded component. Bonded components, whose material thickness is significantly less than a tightly prescribed value less a tolerance that is a rule is small, must in general undergo complex further treatment, which leads to significant extra costs.

A multiplicity of effects are responsible for the occurrence or existence of such lost spaces. Thus, during the curing process the cavity formed by the moulding tools and the overlying vacuum generation system is filled with the fibre-reinforced plastic that has been introduced, in particular with its matrix material. In addition to the form-defining cavity that is required for the design of the bonded component, further undesirable cavities are present. These voids ensue as a result of gaps and/or capillaries between the individual moulding tools, amongst other factors. In addition, empty spaces ensue as a result of volumes underneath the moulding tools that are not filled, as caused by deviations of size and/or location of the laminates, deviations of size and/or location of the moulding tools, and also the thermal expansion of the moulding tools during the heating process in the autoclave in the course of the curing process. In the event of a temperature variation of, for example, 160°C a moulding tool made of a conventional aluminium alloy and with a length of 4000 mm, experiences, for example, an expansion of approx. 15 mm. Furthermore undesirable voids can also form within the vacuum generation system, for example as a result of a vacuum envelope that is not fully fitted, or as a consequence of the very bulky aeration material.

From the prior art Invar alloys for moulding tools and base moulding tools in a wide range of variants are of known art. The "Invar" designation is generally understood to mean an iron-nickel alloy with a content of 36% nickel (FeNi36/1.3912) .

DE 10 2008 036 349 Al concerns a method and also a device for the manufacture of a structure, in particular an aircraft structure, from a fibre-reinforced plastic, wherein in the device those sections of the component remain free of aeration material and/or tear-off material, in which steps or discontinuities are located. In addition the document does not show any moulding tools for purposes of defining the form of reinforcement laminates. Moreover the method starts from reinforcing elements that are at least partially cured, and/or from light metal reinforcements. Accordingly the formation of undesirable voids in the later fibre-reinforced composite component cannot be reduced to the required extent by means of the technical teaching disclosed in DE 10 2008 036 349 Al .

The object of the invention in the first instance is to create a device for the manufacture of components with fibre-reinforced plastics, in which lost cavities either do not any longer occur at all, or only to a very limited extent, so that in particular intolerable reductions in thickness are avoided and what is as a rule complex further treatment for purposes of thickening the components in some regions is omitted. Furthermore it is an object of the invention to specify a method for the manufacture of such components .

This object is achieved in the first instance by means of a device with the features of Claim 1.

In that at least one moulding tool is formed at least partially with a metal alloy that has an anomalous thermal expansion coefficient, temperature-conditioned expansions of the length of the moulding tools are in particular reduced during the curing process of the bonded component in the autoclave, so that the moulding tools no longer project beyond the bonded component as a result of thermal expansion, and thus undesirable lost cavities are to a large extent avoided. Both the at least one base laminate and also the reinforcement laminates are preferably formed from fibre-reinforced plastic, such as, for example, a prepreg material. The reinforcement and base laminates located within the device are only cured after the introduction of the device into an autoclave with the application of pressure and temperature to form a bonded component .

In accordance with an advantageous development of the device provision is made that the metal alloy is in particular FeNi 36/1.3912.

This Invar metal alloy, which finds many applications in engineering, has an anomalous thermal expansion coefficient, so that with the high temperatures prevailing in the autoclave the moulding tools that are made from this alloy are only subjected to a low level of thermal expansion. Alternatively other metal alloys that have a comparable anomalous thermal expansion coefficient can be deployed for the inventive device.

The alloy Fe65Ni35-Invar has the following physical properties, amongst others: a thermal expansion coefficient between 20°C and 90°C of approximately 1.7-2.0Ί0^-6 1/K, a thermal conductivity at 23°C of approximately 13 Wm^_1K^_1, a specific electrical resistance of approximately 75-85 μΏ.οιη, a density of approximately 8 g/cm³ and a tensile strength of approximately 450-590 N/mm².

In an advantageous further development of the invention a seal is fitted in at least some sections of a peripheral contour in a gap-free manner, in particular on at least one end face and/or at least one longitudinal face of the bonded component. By this means, amongst others, matrix material and, under some circumstances, reinforcing fibres are prevented from being flushed out of the bonded component during the autoclave process and/or from penetrating into any lost cavities still present within the device. In addition the seal, by virtue of its elasticity, allows for the compensation of deviations in size and/or location of the at least one base laminate and also of the reinforcement laminates of the bonded component. The peripheral contour of what is, for example, a rectangular bonded component is formed by the two opposing shorter end faces and the longitudinal faces running at right angles to the latter, which are significantly longer than the end faces. In accordance with a further advantageous configuration of the device provision is made that the seal is formed from an elastic material, in particular from a mixture of rubber and cork.

As a consequence of this material composition a high temperature resistance is provided with adequate elasticity and nevertheless a sufficient mechanical load capacity for the seal. Here the cork-rubber mixture is held together by means of a suitable binding agent.

In accordance with a further development of the device the seal is provided on at least one side in at least some sections with an adhesive layer.

By virtue of the adhesive layer the seal is thus reliably secured against slippage in its location at the respective position on the base moulding tool.

In a further advantageous configuration of the invention at least one end face and/or at least one longitudinal face of the at least one moulding tool ends flush with the seal in at least some sections. As a consequence of this configuration of the moulding tools, free of projections or overhangs relative to the bonded component, with a seal fitted, the lost cavities that otherwise exist between the moulding tool overhangs and the base moulding tool, are to a large extent eliminated.

In accordance with a further configuration of the device the aeration material covers the at least one moulding tool and/or the base moulding tool in at least some regions.

By this means the number of lost cavities in the vacuum generation system can in particular be further reduced if regions with small radii of curvature remain free of aeration material. The aeration material is preferably formed with a polyester fleece or a polyester weave that is permeable to air.

In a further configuration of the invention provision is made that at least one corner region, in particular between an upper face of the base moulding tool and at least one end face and/or one longitudinal face of the at least one moulding tool, is free of aeration material. By this means the formation of lost cavities in these zones is reduced, because the relatively inflexible and bulky (stiff) aeration material in these regions in many cases is unable to lie on the tools without forming a gusset, i.e. it can only cling to the latter while forming small voids. Alternatively the aeration material can also be designed to be fully continuous.

In addition the inventive object is achieved by means of a method in accordance with Claim 9, according to which a bonded component with fibre-reinforced plastics is manufactured, in particular using the device in accordance with one of the Claims 1 to 8.

In the course of the inventive method at least one base laminate is placed and aligned on the base moulding tool in the first instance. Fibre-reinforced plastics, in particular prepreg materials, are preferably deployed as base laminates and as reinforcement laminates. On the periphery, i.e. along the end faces and also the longitudinal faces of the base laminate of the bonded component, a seal is then fitted in a gap-free manner, as least on some sections. Reinforcement laminates are next shaped onto the moulding tools. The moulding tools are then assembled into a group with the reinforcement laminates that are located on them, and are placed as a unit on the base laminate. The moulding tools can then be provided with an optionally perforated release layer, which for its part is overlaid in at least some regions with an aeration material, which together with the vacuum envelope that is yet to be fitted represents the vacuum generation system of the device. Here corner regions between the moulding tools and the base moulding tool are in particular not overlaid with the aeration material, i.e. the aeration material has openings in these zones in order to reduce lost cavities in these sections. In addition further functional layers, such as, for example, release layers, tear-off layers, or resin removal layers, can be provided on the base moulding tool and/or on the moulding tools, in at least some sections, and also on and/or underneath the aeration material. The whole system is then covered with a vacuum envelope to complete the device. The vacuum envelope can be subjected to reduced pressure to achieve a partial vacuum via at least one vacuum channel with at least one perforated covering accommodated therein. For purposes of curing the adhesive component formed from the at least one base laminate and the at least one reinforcement laminate by the application of pressure and/or temperature the whole device is placed in an autoclave. After the curing process is completed the device can be taken out of the autoclave, and the bonded component, cured to form a finished component, in particular an integrally reinforced shell, can be extracted. In the course of the curing process the device remains in the autoclave.

In the drawing:

Fig. 1 shows a cross-sectional representation through an arrangement of known prior art for the production of fibre-reinforced plastic components.

Fig. 2 shows a longitudinal section through the arrangement of Fig. 1 along the section line II - II,

Fig. 3 shows a longitudinal section through an inventive device with moulding tools made from a metal alloy with an anomalous thermal expansion coefficient,

Fig. 4 shows the device in accordance with Fig. 3 with an optional seal,

Fig. 5 shows a magnified representation of part of the device from Fig. 4, but with moulding tools optionally embodied free of projections, and

Fig. 6 shows the device in accordance with Fig. 3, but with aeration material partially provided,

In the drawings the same design elements have the same reference numbers in each case.

Fig. 1 shows a schematic cross-section through an arrangement of known prior art for the manufacture of components from fibre-reinforced plastics, while Fig. 2 - to which reference is made at the same time - illustrates a simplified longitudinal section through the arrangement in accordance with the section line II-II in Fig. 1.

The arrangement 10 comprises, amongst other items, a base moulding tool 12 with a vacuum channel 14, into which is inserted a perforated covering 16. On the base moulding tool 12 is located a base laminate 18, on which three reinforcement laminates 20 are laid down; together these form the bonded component 22, and after this has been cured in the autoclave, embody the prefabricated component that is to be manufactured, such as, for example, an integrally reinforced shell, or similar. The spatial geometry of the reinforcement laminates 20 is here defined by means of three moulding tools 24, i.e. cores. On the moulding tools 24 runs a release layer 26, which for its part is covered with an aeration material 28. The aeration material 28 is covered with a vacuum envelope 30, wherein a seal 32 is arranged between the vacuum envelope 30 and the base moulding tool 12, so that a gas-tight closure of the vacuum generation system thus formed is achieved relative to the external environment. The at least one base laminate 18 and the reinforcement laminates 20 are formed from a fibre- reinforced plastic. In aerospace a prepreg material made up from an epoxy resin reinforced with fibres, i.e. fibre rovings, often finds application as the fibre-reinforced plastic (FRP) . Within the device 10 a multiplicity of undesirable voids 34 form, in particular during the curing process of the bonded component 22 - in which the whole arrangement 10 is placed in an autoclave, and a reduced pressure prevails within the vacuum envelope 30 for at least some of the time. As can be seen from Figs. 1, 2 the voids 34 exist between each of the moulding tools 24, and a further void 34 in the form of a gusset is located underneath the aeration material 28 within the vacuum generation system. The other voids 34 are to be attributed to, amongst other factors, thermal expansion effects of the moulding tools 24 and/or of the base moulding tool 12 in the course of the curing process in the autoclave. Matrix material can flow into the voids 34, as a result of which a material thickness of the bonded component 22 can be reduced to the extent that this, less the prescribed tolerance, lies below a prescribed limiting value, and complex rework is required in order to bring the bonded component 22 up to the required minimum design thickness.

Fig. 3 shows a simplified representation of a device in accordance with the invention. In the interests of improving the clarity of the drawing the vacuum generation system is not represented. The device 40 comprises, amongst other items, a base moulding tool 42 with an integrated vacuum channel 44 and a perforated covering 46 arranged in the latter. A reduced pressure, i.e. a partial vacuum, can be built up in the vacuum generation system, not represented here, via the vacuum channel 44. On the base moulding tool 42 are laid down a base laminate 48 and a reinforcement laminate 50; together these form the bonded component 52, which, after completion of the curing process in the autoclave, represents the finished bonded component, i.e. the prefabricated component, such as, for example, an integrally reinforced shell made of fibre-reinforced plastics, or similar. The bonded component 52 is accommodated between the base moulding tool 42 and at least one (upper) moulding tool 54. The base moulding tool 42 forms together with the moulding tool 54 a so-called "bonded component cavity", which serves the purpose of moulding, i.e. defining the form, of the initially still soft, i.e. not yet cured, bonded component 52. In accordance with one aspect of the invention the at least one moulding tool 54 is formed from a metal alloy, which - as indicated by the horizontal white double arrow - has an anomalous, i.e. very small, thermal expansion coefficient as the temperature fluctuates. The at least one moulding tool 54 is preferably formed from a metal alloy with the composition FeNi 36/1.3912 (Invar). Alternatively the moulding tool 54 can be formed from a preferred thermo^¬ setting plastic material, if this has a sufficiently small thermal expansion coefficient, the necessary temperature resistance, and a sufficient mechanical load capacity. By virtue of the negligibly small thermal expansion 56 of the moulding tool 54 manufactured from the Invar metal alloy, any increasing projection of the bonded component 52 as a result of thermally-conditioned moulding tool overhangs 58, primarily as a consequence of the expansion of the moulding tool 54 during the heating phase of the curing process, is significantly reduced.

Fig. 4 illustrates the device in accordance with Fig. 3, but with an additional peripheral seal.

The device 40 comprises in turn the base moulding tool 43 and the moulding tool 54 for purposes of creating the form- defining cavity for the bonded component 52. The base moulding tool 42 is fitted with the vacuum channel 44 and with the perforated covering 46 to allow the connection of a vacuum pump. In contrast to Fig. 3 the device 40 is here provided with an optional, preferably peripheral, seal 60. The upper moulding tool 54 is preferably manufactured from a metal alloy with a low thermal expansion coefficient, such as Invar, for example. The seal 60 is arranged between the moulding tool overhangs 62, here taken into account in the design, and the base moulding tool 42, and is preferably fitted in a gap-free manner on at least one end face 68 and/or at least one longitudinal face of the bonded component 53, at least on some sections. The seal is preferably provided on those sections of the end faces and/or longitudinal faces of the bonded component in which the largest reductions in thickness are to be anticipated as a result of undesirable flows of the matrix material out of the bonded component 52 into lost cavities during the autoclave process.

In the example of embodiment shown in Fig. 4 the seal 60 is additionally provided on its lower face with a thin adhesive layer 64 for purposes of securing its location on the base moulding tool 42. The seal 60 is preferably manufactured from a mixture of cork and rubber, together with a binding agent, which has a sufficient elasticity and thermal load-bearing capability. For this purpose suitable mixing proportions of the cork, rubber and the binding agent are to be produced.

By means of the seal 60 in the region of the peripheral contour (end faces/longitudinal faces) of the bonded component 52 in the first instance any possible transfer of matrix material into the vacuum generation system, i.e. into the voids formed by the vacuum generation system, is reduced. In addition the seal 60 reduces voids in the region of the bonded component 52, which arise in particular as a result of deviations of location and/or dimension of the base and reinforcement laminates 48, 50 and also of the at least one moulding tool 54. The seal 60 is preferably attached to the base laminate 48 in a gap- free manner after the base laminate 48 has been laid down on the base moulding tool 42. The at least one moulding tool 54, together with the reinforcement laminate 50 that is shaped on the latter, is then introduced, and aligned and laid down on the base laminate 48. The reinforcement laminate 50, supported on the seal 60, in at least some regions as required, does not lead to any conflict, because the elastic seal 60 is compressed and/or displaced by the reinforcement laminate 50.

Fig. 5 shows a magnified representation of part of the device in accordance with Fig. 4, wherein in contrast to the latter the moulding tool is free of projections (including seal) and a simplified vacuum generation system is also represented. The device 40 comprises the base moulding tool 44 with the vacuum channel 44 located therein, and the perforated covering 46 accommodated in the vacuum channel. The bonded component 52 located between the moulding tool 54 comprises the base laminate 48 and the reinforcement laminate 50. The optional seal 60 with the adhesive layer 64 here arranged on the lower face of the latter is arranged in the example of embodiment shown in Fig. 5 at least on some sections along at least one end face 68 of the bonded component 52, i.e. of the base laminate 48 and the reinforcement laminate 50. Additionally or alternatively the seal 60 can also be provided in the region of the end face, not represented here, opposing the end face 68, and/or of at least one longitudinal face, likewise not marked, of the bonded component 52. The seal 60 preferably surrounds the peripheral contour (end faces/longitudinal faces) of the bonded component 52 completely and is moreover designed to be continuous, i.e. free of openings. The moulding tool 54 is preferably formed from Invar.

In contrast to the form of embodiment in accordance with Fig. 4 an end section 70 of the moulding tool 54 is designed free of projections, i.e. overhangs, in relation to the bonded component 52 including the seal 60, that is to say a horizontal separation distance 72 between the seal 60 and a moulding tool end face 74 is here approximately zero, so that the moulding tool end face 74 ends essentially flush with the seal 60. A further end section of the moulding tool 54, not represented here, located opposite to the end section 70 of the moulding tool 54, is preferably designed in a corresponding manner to the end section 70 of the moulding tool 54. The same is true for at least one longitudinal face of the at least one moulding tool 54.

A vacuum generation system, not provided with a reference number, of the device 40, is formed with, amongst other items, a release layer 76, which rests on the moulding tool 54 and the base moulding tool 42. The release layer for its part is covered with an aeration material 78, which in turn is overlaid with a vacuum envelope 80. In addition to the release layer 76 and the aeration material 78 further functional layers, such as, for example, tear-off layers and/or resin removal layers, can be provided in the vacuum generation system. By means of the seal 82 the vacuum envelope 80 forms a hermetically sealed space. In this manner a reduced pressure, i.e. a partial vacuum, can be generated underneath the vacuum envelope 80 via the vacuum channel 44. By virtue of the configuration of the end section 70 of the moulding tool 54 here shown, which is free of projections, i.e. overhangs, the moulding tool 54 no longer projects over the end face 68 of the bonded component 52 - including the seal 60 - so that fewer undesirable lost cavities can form.

Fig. 6 shows a scrap section of the device in accordance with Fig. 5, but with aeration material that is only partially provided. The device 40 comprises the base moulding tool 42 and the moulding tool 54 with the bonded component 52 accommodated in between; the latter is in turn built up from the at least one base laminate 48 and at least one reinforcement laminate 50. The seal 60 is fitted on the end face 68 of the bonded component 52, ideally in a gap-free manner. The vacuum channel 44 and the perforated covering 46 are integrated into the base moulding tool 42. The moulding tool 54, together with an upper face 84 of the base moulding tool 42, are overlaid with the optional release layer 76.

In contrast to the form of embodiment in Fig. 5 the release layer 76 is only overlaid with the aeration material 78 is some regions. As a rule the aeration material 78 takes the form of a relatively stiff surface textile weave, in particular a polyester fleece and/or a polyester weave. The largely inflexible, very thick aeration material 78 is unable to lie close to zones of the device 40 with only small radii of curvature (so-called discontinuities, steps, levels) , so that multiple undesirable gusset-type cavities form underneath the vacuum envelope 80.

For purposes of avoiding this effect a corner region 86 between the vertical end face 74 of the moulding tool 54, i.e. of the seal 60, and the horizontal upper face 84 of the base moulding tool 42 is not overlaid with the aeration material 74, i.e. the aeration material 78 has a cut-out 88 in the corner region 86. By this means the occurrence of undesirable cavities in the vacuum generation system underneath the vacuum envelope 80, i.e. the release layer 76, in the corner region 86 is in particular reduced; these otherwise form easily by virtue of the stiff, inflexible aeration material 78 in these regions, as a result of folds or waves in the aeration material 78. In addition the risk of any matrix material flowing out of the bonded component 52 - during the curing process in the autoclave - into these lost cavities, notwithstanding the presence of the seal 60, is further minimised. This in turn has the consequence that undesirable reductions of the thickness of the bonded component 52, in particular in the region of the end face 68, are avoided. In a variation from the relief of the corner region 86, here just shown in an exemplary manner, the overlay of other regions of the moulding tool 54 and/or the base moulding tool 42 with the aeration material 78 can also be eliminated as required. Thus the partial removal of the aeration material 78 in the corner region 86 reduces any possible losses of matrix material of the bonded component 52 due to the avoidance of voids into which matrix material from the bonded component 52 can infiltrate as a result of a fall in pressure. The cut-out 88 is to be dimensioned with regard to its size and position such that a proper evacuation of the vacuum generation system is ensured. The aeration material 78 is itself usually covered in turn with the vacuum envelope 80 and by means of the seal 82 is sealed with respect to the base moulding tool 42. A reduced pressure, i.e. a partial vacuum, can be built up and maintained underneath the vacuum envelope 80 via the vacuum channel 44 by means of a vacuum pump. The aeration material 78 can be manufactured, for example, with a continuous (one-piece) surface textile weave, into which cut-outs can preferably be introduced so as to come to lie in the corner regions. Alternatively a plurality of sections or strips of the aeration material 78, spaced apart from one another, can be positioned onto the release layer 76, or the upper face 84 of the base moulding tool 42, so as to create the cut-out 88.

Compared with arrangements of prior known art for the production of such bonded components, undesirable cavities are reduced and the reductions in laminate thickness of the bonded component that result from such cavities are minimised, as are the consequential rework costs. For the most effective possible minimisation of undesirable lost cavities the device 40 can comprise at least one of the above described provisions (cf. in particular Figs. 3 to 6) , namely at least one moulding tool 54 with a low thermal expansion, at least one moulding tool 54 free of projections, i.e. overhangs, a seal 60 arranged in at least some sections of the periphery of the bonded component, and also an aeration material 78 that is only applied in some regions. In conclusion the device 40 enables the manufacture, in a reliable process that is suitable for series production, of bonded components with fibre- reinforced plastics that are of high quality, dimensionally stable, and require no rework, such as, for example, integrally reinforced (shell) components that at the present time find widespread application in the manufacture of aircraft.

Reference symbol list

10. Arrangement

12. Base moulding tool

14. Vacuum channel

16. Perforated covering

18. Base laminate

0. Reinforcement laminate

2. Adhesive component

4. Moulding tool

6. Release layer

8. Aeration material

30. Vacuum envelope

32. Seal

34. Void (undesirable)

40. Device

42. Base moulding tool

44. Vacuum channel

46. Perforated covering

48. Base laminate

50. Reinforcement laminate

52. Adhesive component

54. Moulding tool

56. Thermal expansion

58. Moulding tool overhang (thermal)

60. Seal (peripheral)

62. Moulding tool overhang (design)

64. Adhesive layer

66. Deviation in size and/or location

68. End face (bonded component)

70. End section (moulding tool)

72. Separation distance

74. End face (moulding tool)

76. Release layer

78. Aeration material

80. Vacuum envelope

82. Seal Upper face Corner region Opening

Claims

PATENT CLAIMS

1. A device (40) for the manufacture of a bonded component (52) with fibre-reinforced plastics with at least one base moulding tool (42) and at least one moulding tool (54), wherein the bonded component (52) is arranged between the base moulding tool (42) and the moulding tool (54), and the bonded component (52) has at least one base laminate (48) and at least one reinforcement laminate (50), and the moulding tool (54) is covered with an aeration material (78) and with a vacuum envelope (80), wherein the vacuum envelope (80) is sealed with respect to the base moulding tool (42), characterised in that, at least one moulding tool (54) is at least partially formed from a metal alloy, which has an anomalous thermal expansion coefficient.

2. The device (40) in accordance with Claim 1, characterised in that, the metal alloy is in particular FeNi 36/1.3912.

3. The device (40) in accordance with Claim 1 or 2, characterised in that, a seal (60) is fitted in at least some sections of a peripheral contour in a gap-free manner, in particular on at least one end face (68) and/or at least one longitudinal face of the bonded component (52) .

4. The device (40) in accordance with Claim 3, characterised in that, the seal (60) is formed from an elastic material, in particular from a mixture of rubber and cork.

5. The device (40) in accordance with Claim 3 or 4, characterised in that, the seal is provided on at least one side in at least some sections with an adhesive layer (64) .

6. The device (40) in accordance with one of the Claims 1 to 5 , characterised in that, at least one end face (74) and/or at least one longitudinal face of the at least one moulding tool (54) ends flush with the seal (60) in at least some sections .

7. The device (40) in accordance with one of the Claims 1 to 6, characterised in that, the aeration material (78) covers the at least one moulding tool (54) and/or the base moulding tool (42) in at least some regions.

8. The device (40) in accordance with Claim 7, characterised in that, at least one corner region (86), in particular between an upper face (84) of the base moulding tool (42) and at least one end face (74) and/or one longitudinal face of the at least one moulding tool (54), is free of aeration material (78) .

9. A method for the manufacture of a bonded component (52) with fibre-reinforced plastics, in particular using the device (40) in accordance with one of the Claims 1 to 8.